Coil for rotary electric machine and rotary electric machine with it

ABSTRACT

A coil ( 3 ) for a rotary electric machine ( 3 ) is constituted by eight layers, and includes an inner coil member ( 10 B) constituting one layer, three layers, five layers, and seven layers, and an outer coil member ( 10 A) constituting two layers, four layers, six layers, and eight layers. An outer upper right arm bending part ( 31 ), an outer upper left arm bending part ( 32 ), an outer lower right arm bending part ( 33 ), and an outer lower left arm bending part ( 34 ) of the outer coil member ( 10 A) are formed, at a position where some portions are not overlaid on each other, when six inner coil members ( 10 B) constituting seven layers are arranged to be overlaid on six outer coil members ( 10 A) constituting eight layers.

BACKGROUND OF THE INVENTION Field of the Invention

The present invention relates to a coil for a rotary electric machine,and a rotary electric machine having it.

Description of the Related Art

Conventionally, a coil formed into a cylindrical shape by spirallywinding a conductor assembly formed into a belt-like shape by laminatingplural conductors molded into a predetermined waveform shape is known asa coil for a rotary electric machine (Japanese Patent No. 5812145).

In Japanese Patent No. 58121.45, the plural conductors are formed intosuch a waveform having a base part (slot housing part) inserted in aslot of a stator core constituting the rotary electric machine, and aconnection part (turn part) respectively connecting one end and theother end of adjacent base parts projecting from the slot. Also, inJapanese Patent No. 5812145, a crank part bent in a radial direction ofthe stator core is formed at a peak part the most away from the statorcore of the connection part, and a small crank part with a smallerbending amount than that of the crank part is formed at a joint part ofthe base part connected to the connection part, so as to preventinterference between the adjacent conductors.

To avoid interference between adjacent small crank parts, for example,there is a need for displacing the small crank parts in an axial linedirection of the stator core, so a projection amount of the coil fromthe stator core becomes large. To avoid it, width of the small crankpart is made narrower than that of other portions in Japanese Patent No.5812145, so there is a need of a processing step, which results indeterioration of costs. Furthermore, the width of the small crank partsis narrower than that of the other portions, so a conductor resistanceis deteriorated.

SUMMARY OF THE INVENTION

The present invention is made in light of such a circumstance, and anobject of the present invention is to provide a coil for a rotaryelectric machine, by which the deteriorations of the conductorresistance and costs can be prevented, and a rotary electric machinehaving it.

The coil for the rotary electric machine according to the presentinvention is formed into an annular shape by plural coil members, and isinserted in plural slots provided on an annular stator of the rotaryelectric machine. The plural coil members respectively comprise pluralbase parts inserted in the slots, extending in an axial line directionof the coil, and having a gap in a circumferential direction of thecoil, plural first connection parts projecting from one end of the slotand connecting ends of the adjacent base parts to each other, and pluralsecond connection parts projecting from the other end of the slot andconnecting the other ends of the adjacent base parts to each other. Thefirst and second connection parts respectively comprise two armsextending from one end and the other end of each of the adjacent baseparts so that they approach to each other, and an arm connection partconnecting the two arms. The coil members are arranged in line in thecircumferential direction of the coil, and are inserted in the same slotin the radial direction of the coil. The coil members adjacent to eachother in the same slot in the radial direction of the coil arephase-offset from each other and thus arranged. In the two arms, an armbending part bent in the radial direction of the coil is respectivelyprovided at a joint part of the arm, the joint part being positioned notto overlay on the other coil member in the radial direction of the coil.The phase-offset means that the positions of the first connection partsof the coil members adjacent in the same slot in the radial direction ofthe coil are offset from each other when seen in a side view.

According to the present invention, the arm bending part is bent at aposition where it is not overlaid on the other coil member. There is noneed of making thickness of the arm bending part thinner than otherportions, so deterioration of the conductor resistance can be prevented.Also, there is no need of a processing step, so cost deterioration canbe prevented.

Preferably, the arm connection part is bent in the radial direction ofthe coil.

In this constitution, the coil members adjacent to each other in thecircumferential direction of the coil can be arranged withoutinterference.

Preferably, the arm bending part is bent in one of an inner directionand an outer direction in the radial direction of the coil, and the armconnection part is bent in the other of the inner direction and theouter direction in the radial direction of the coil.

In this constitution, the arm bending part is bent in one of the innerdirection and the outer direction in the radial direction of the coil,and the arm connection part is bent in the other of the inner directionand the outer direction in the radial direction of the coil, so that theplural coil members can be respectively returned to the same position inthe radial direction of the coil.

Preferably, the arm connection part extends in the circumferentialdirection of the coil.

In this constitution, compared to the arm connection part not extendingin the circumferential direction of the coil, the arm connection partcan be gradually bent in the radial direction of the coil. Also,compared to the arm connection part sharply bent, a load applied to thearm connection part can be reduced.

Preferably, the arm is bent at an angle of about 45 degrees in thecircumferential direction of the coil. About 45 degrees means an anglein a range of 45±5 degrees.

In this constitution, the arm bending part of the arm can be formed inan almost rectangular shape. Furthermore, compared to the arm bent at anangle smaller than 45 degrees for example, 30 degrees), the arm bendingpart of the arm can be formed in a wider range, so as to reduce a loadapplied to the coil.

Preferably, the arm is bent plural times at different angles in thecircumferential direction of the coil.

In this constitution, for example, after the arm is bent at a firstinclination angle, it can be bent at an inclination angle smaller thanthe first inclination angle. Thereby, compared to the arm bent at thesame inclination angle (for example, first inclination angle), aprojection amount of the atm in the axial line direction of the coil canbe made small, and a space for the arm bending part can be secured.Preferably, the first inclination angle is 45 degrees.

Preferably, among the plural coil members, the arm bending part of aterminal end of the coil member arranged on the innermost peripheralside in the radial direction of the slot is bent in an outer directionof the radial direction of the coil.

In this constitution, the arm bending part of the terminal end of thecoil member can be prevented from contacting a rotor provided inside astator core.

Preferably, one of the two arms is positioned at a reference position inthe radial direction of the coil, and the other is positioned at aprojection position at which it projects nearer an inner side than thereference position. Among the two arms, arms positioned at the referenceposition of the coil members adjacent to each other in the radialdirection of the coil are faced to each other, and the other armspositioned at the projection position are faced to each other.

In the coil members adjacent to each other in the radial direction ofthe coil, when one arm positioned at the reference position is faced tothe other arm positioned at the projection arm, one arm of the coilmember inside in the radial direction (reference position) interfereswith the other arm of the coil member outside in the radial direction(projection position), so the coil member cannot be arranged.

In the coil members adjacent to each other in the radial direction ofthe coil, when one arm positioned at the reference position is faced tothe arm positioned at the projection position, a waste space isgenerated between one arm of the coil member outside in the radialdirection (reference position) and the other arm of the coil memberinside in the radial direction (projection position), thereby enlargingthe size of the coil.

According to this constitution, in the coil member adjacent to eachother in the radial direction of the coil, the arms positioned at thereference position are faced to each other, and the other armspositioned at the projection position are faced to each other.Therefore, the arms do not interfere with each other, and the coilmembers can be reliably arranged. Also, there is no waste space betweenthe arms faced to each other, so that enlargement of the coil can beprevented.

The rotary electric machine according to the present invention comprisesa coil for the rotary electric machine, and a stator that is formed in acylindrical shape and on the inner periphery of which plural slots inwhich plural base parts of the coil for the rotary electric machine areinserted, are formed.

By the rotary electric machine according to the present invention,deteriorations of the conductor resistance and costs can be prevented.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top view showing a coil for a rotary electric machine and astator to which it is mounted, in one embodiment of the presentinvention;

FIG. 2 is an exploded perspective view showing a stator core and an8-layer outer coil member;

FIG. 3 is a top view of an outer coil member;

FIG. 4 is a front view of an outer coil member;

FIG. 5 is a top view of an inner coil member;

FIG. 6 is a front view of an inner coil member;

FIG. 7 is a front view showing a status that two outer coil members arealigned,

FIG. 8 is a front view showing a status that six outer coil members arealigned;

FIG. 9 is a perspective view showing a status that a first outer coilmember is mounted to a stator core;

FIG. 10 is a perspective view showing a status that first and secondouter coil members are mounted to the stator core;

FIG. 11 is a perspective view showing a status that first to sixth outercoil members are mounted to the stator core;

FIG. 12 is a perspective view showing a status that the first to sixthouter coil members and a first inner coil member are mounted to thestator core;

FIG. 13 is a perspective view showing a status that the first to sixthouter coil members and first to sixth inner coil members are mounted tothe stator core;

FIG. 14 is a front view showing a status that the first to sixth outercoil members are overlaid on the first to sixth inner coil members;

FIG. 15 is a front view showing a status that the first outer coilmember is overlaid on the third inner coil member;

FIG. 16 is a front view showing a status that the third outer coilmember is overlaid on the first inner coil member; and

FIG. 17 is a front view showing an enlarged outer coil member in asecond embodiment.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

With reference to drawings, a coil for a rotary electric machine in oneembodiment of the present invention will be explained as follows.

As shown in FIGS. 1 and 2, a rotary electric machine 8 such as anelectric motor and a generator comprises a stator 1 formed into acylindrical shape, and a rotor (not shown) rotatably arranged inside thestator 1.

The stator 1 comprises a stator core 2, and a coil 3 according to thepresent invention. The stator core 2 has a cylindrical shape, and isprovided with plural (for example, in this embodiment, 72) slots 2 apenetrating in a rotary axial direction are spaced from each other in acircumferential direction.

In this embodiment, a slot 2 a at a predetermined position is referredto as a first slot 2 a, and slots are referred to as second, third to27th slots 2 a sequentially in a counterclockwise direction.

The coil 3 comprises an outer coil member 110A and an inner coil member10B formed at the same thickness. The 24 outer coil members 10A and the24 inner coil members 10B are respectively provided, and inserted in theslots 2 a of the stator core 2. Also, FIGS. 1, 2, 9 to 13 generally showthe first outer coil member 10A and the second outer coil member 10A.

The coil 3 is sequentially inserted in an inner coil member 10B, anouter coil member 10A, an inner coil member 10B, an outer coil member10A, an inner coil member 10B, an outer coil member 110A, an inner coilmember 10B, and an outer coil member 10A from inside in the radialdirection of the stator core 2, in one slot 2 a.

In this embodiment, first to eighth layers are sequentially alignedtoward outside from inside in the radial direction of the stator core 2.That is to say, the first, third, fifth and seventh layers areconstituted by the inner coil members 110B, and the second, fourth,sixth and eighth layers are constituted by the outer coil members 10A.

The coil 3 comprises six inner coil members 10B in each layer of thefirst, third, fifth and seventh layers, and so total of 24 inner coilmembers 10B are therein.

The coil 3 comprises six outer coil members 10A in each layer of thesecond, fourth, sixth and eighth layers, and so total of 24 outer coilmembers 10A are therein.

[Outer Coil Member]

As shown in FIGS. 3 and 4, the outer coil member 10A is, for example, aflat angle conductor wire type, and comprises first to twelfth outerbase parts 12 a to 12 l inserted in the slots 2 a, and first to fifthouter upper connection parts 13 a to 13 e (first connection parts)connecting upper ends (ends) of the first to twelfth outer base parts 12a to 12 l adjacent to each other. Also, the outer coil member 10Acomprises first to sixth outer lower connection parts 14 a to 14 f(second connection parts) connecting lower ends (other ends) of thefirst to twelfth outer base parts 12 a to 12 l adjacent to each other.

The first outer upper connection part 13 a connects an upper end of thesecond outer base part 12 b to an upper end of the third outer base endpart 12 c. The second outer upper connection part 13 b connects an upperend of the fourth outer base part 12 d to the upper end of the fifthouter base part 12 e. The third outer upper connection part 13 cconnects the upper end of the sixth outer base part 12 f to the upperend of the seventh outer base part 12 g.

The fourth outer upper connection part 13 d connects the upper end ofthe eighth outer base part 12 h to the upper end of the ninth outer basepart 12 i. The fifth outer upper connection part 13 e connects the upperend of the tenth outer base part 12 j to the upper end of the eleventhouter base part 12 k.

The first outer lower connection part 14 a connects the lower end of thefirst outer base part 12 a to the lower end of the second outer basepart 12 b. The second outer lower connection part 14 b connects thelower end of the third outer base part 12 c to the lower end of thefourth outer base part 12 d. The third outer lower connection part 14 cconnects the lower end of the fifth outer base part 12 e to the lowerend of the sixth outer base part 12 f.

The fourth outer lower connection part 14 d connects the lower end ofthe seventh outer base part 12 g to the lower end of the eighth outerbase part 12 h. The fifth outer lower connection part 14 e connects thelower end of the ninth outer base part 12 i to the lower end of thetenth outer base part 12 j. The sixth outer lower connection part 14 fconnects the lower end of the eleventh outer base part 12 k to the lowerend of the twelfth outer base part 12 l.

The first to fifth outer upper connection parts 13 a to 13 e are formedinto the same shape, and have outer upper right arms 16 a and outerupper left arms 16 b, and an outer upper arm connection part 17extending in a circumferential direction (a horizontal direction in FIG.4) of the stator core 2, and connecting the outer upper right 16 a andthe outer upper left arm 16 b.

The outer upper right arms 16 a of the first to fifth outer upperconnection parts 13 a to 13 e are respectively connected to the second,fourth, sixth, eighth and tenth outer base parts 12 b, 12 d, 12 f, 12 hand 12 j. The outer upper left arms 16 b of the first to fifth outerupper connection parts 13 a to 13 e are respectively connected to thethird, fifth, seventh, ninth and eleventh outer base parts 12 c, 12 e,12 g, 12 i and 12 k.

The outer upper right arms 16 a and the outer upper left arms 16 b ofthe first to fifth outer upper connection parts 13 a to 13 erespectively extend in a manner to approach to each other, while beingbent in the circumferential direction (the horizontal direction of FIG.4) of the stator core 2.

The outer upper right arms 16 a of the first to fifth outer upperconnection parts 13 a to 13 e have respective first outer inclinationparts 16 c which are respectively connected to the second, fourth,sixth, eighth and tenth outer base parts 12 b, 12 d, 12 f, 12 h and 12 jand whose inclination angle (angle in the horizontal direction) is at afirst predetermined angle (for example, 45 degrees). Also, therespective outer upper right arms 16 a have respective second outerinclination parts 16 d which are connected to the respective first outerinclination parts 16 c and whose inclination a is smaller than the firstpredetermined angle (for example, 28 degrees). The respective outerupper left arms 16 b of the first to fifth outer upper connection parts13 a to 13 e are formed horizontally symmetrically to the respectiveouter upper right arms 16 a of the first to fifth outer upper connectionparts 13 a to 13 e.

First to sixth outer lower connection parts 14 a to 14 f are formed intothe same shape, and comprise outer lower right arras 18 a and outerlower left arms 18 b, and outer lower arm connection parts 19 extendingin the circumferential direction (the horizontal direction in FIG. 4) ofthe stator core 2, and connecting the outer lower right arms 18 a andthe outer lower left arms 18 b.

The outer lower right arms 18 a and the outer lower left arms 18 b ofthe first to sixth outer lower connection parts 14 a to 14 f areconnected to the first to twelfth outer base parts 12 a to 12 l, andextend in a manner to approach to each other while being bent in thecircumferential direction (the horizontal direction in FIG. 4) of thestator core 2, respectively. The outer lower right arms 18 a and theouter lower left arms 18 b of the first to sixth outer lower connectionparts 14 a to 14 f are respectively formed vertically symmetrical to theouter upper fight arms 16 a and the outer upper left arms 16 b of thefirst to fifth outer upper connection parts 13 a to 13 e.

An outer right end 21 bent in the circumferential direction (thehorizontal direction in FIG. 3) of the stator core 2 and then extendingupward is connected to an upper end of the first outer base part 12 a.An outer left end 22 bent in the circumferential direction (thehorizontal direction in FIG. 4) of the stator core 2 and then extendingupward is connected to an upper end of the twelfth outer base part 12 l.

The outer coil member 10A is bent in the radial direction (the verticaldirection in FIG. 3) of the stator core 2, and divides a position of theouter coil member 10A in the radial direction of the stator core 2 intothree positions. In this embodiment, in FIG. 4, three positions areshown by three kinds of different hatching patterns.

The outer upper left arms 16 b, the outer lower left arms 18 b and theouter left ends 22 are located at a reference position of the outer coilmember 10A indented to an outermost side in the radial direction of thestator core 2. The respective parts 16 b, 18 b, 22 are shown by hatchingpatterns of lines extending from a lower left side to an upper rightside.

The first to twelfth outer base parts 12 a to 12 l are located to a 0.5T projecting position projecting by 0.51 (T is thickness of the outercoil member 10A in the radial direction of the stator core 2) from thereference position in the radial direction of the stator core 2. Thefirst to twelfth outer base parts 12 a to 12 l at the 0.5 T projectingposition are shown by hatching patterns of lines extending from an upperleft side to a lower right side.

The outer upper fight arms 16 a, the outer lower right arms 18 a and theouter right ends 21 are located at a 1 T projecting position of theouter coil member 10A projecting to an inner side by 1 T from thereference position in the radial direction of the stator core 2. Therespective parts 16 a, 18 a and 21 at the 1 T projecting positionreference position are shown by hatching pattern of lines extendingupward and downward.

Outer upper right arm bending parts 31 bent to an outer side by 0.5 T inthe radial direction of the stator core 2 are formed on the outer upperright arms 16 a at joint portions connected to the second, fourth,sixth, eight and tenth outer base parts 12 b, 12 d, 12 f, 12 h and 12 j.

Outer upper left arm bending parts 32 bent to an inner side by 0.5 T inthe radial direction of the stator core 2 are formed on the outer upperleft arms 16 b at joint portions connected to the third, fifth, seventh,ninth and eleventh outer base parts 12 c, 12 e, 12 g, 12 i and 12 k.

An outer upper arm connection part 17 is bent to an outer side by 1 T inthe radial direction of the stator core 2, from a right end (1 Tprojecting position) connected to the outer upper right arm 16 a to aleft end (reference position) connected to the outer upper left arm 16b.

Outer lower right arm bending parts 33 bent to an outer side by 0.5 T inthe radial direction of the stator core 2 are formed on the outer lowerright arms 18 a at joint portions connected to the first, third, fifth,seventh, ninth and eleventh base parts 12 a, 12 c, 12 e, 12 g, 12 i and12 k.

Outer lower left arm bending parts 34 bent to an inner side by 0.51 T inthe radial direction of the stator core 2 are formed on the outer lowerleft arms 18 b at joint portions connected to the second, fourth, sixth,eighth, tenth and twelfth base parts 12 b, 12 d, 12 f, 12 h, 12 j and 12l.

An outer lower arm connection part 19 is bent to an outer side by 1 T inthe radial direction of the stator core 2 from a right end (1 Tprojecting position) connected to the outer lower right arm 18 a to aleft end (reference position) connected to the outer lower left arm 18b.

A right end bending part 35 bent to an outer side by 0.5 T in the radialdirection of the stator core 2 is formed on an outer tight end 21 at aportion connected to the first outer base part 12 a.

A left end bending part 36 bent to an inner side by 0.5 T in the radialdirection of the stator core 2 is formed on an outer left end 22 at aportion connected to the twelfth outer base part 12 l.

[Inner Coil Member]

As shown in FIGS. 5 and 6, an inner coil member 10B is of a flat-angleconductor type, and is formed into a shape horizontally symmetrical toan outer coil member 10A. Detailed explanation thereof will besimplified.

The inner coil member 10B comprises first to twelfth inner base parts 42a to 42 l inserted in the slots 2 a, and first to fifth inner upperconnection parts 43 a to 43 e connecting upper ends (ends) of the firstto twelfth inner base parts 42 a to 42 l adjacent to each other. Also,the inner coil member 10B comprises first to sixth inner lowerconnection parts 44 a to 44 f connecting lower ends (other ends) of thefirst to twelfth inner base parts 42 a to 42 l adjacent to each other.

The first to fifth inner upper connection parts 43 a to 43 e are formedinto the same shape, and comprise inner upper right arms 46 a, innerupper left arms 46 b, and inner upper arm connection parts 47.

The inner upper right arm 46 a comprises a first inner inclination part46 c, and a second inner inclination part 46 d. The inner upper left arm46 b is formed horizontally symmetrical to the inner upper right arm 46a.

The first to sixth lower connection parts 44 a to 44 f are formed intothe same shape, and comprise inner lower right arms 48 a, inner lowerleft arms 48 b, and inner lower arm connection parts 49.

An inner right end 51 is connected to an upper end of the first innerbase part 42 a. An inner left end 52 is connected to an upper end of thetwelfth inner base part 42 l.

The inner upper right arms 46 a, the inner lower right arms 48 a and theinner left ends 52 are located at a reference position of the inner coilmember 10B indented to an outermost side in the radial direction of thestator core 2. The respective parts 46 a, 48 a, 52 at the referenceposition are shown by hatching patterns of lines extending from a lowerleft side to an upper right side.

The first to twelfth inner base parts 42 a to 42 l are located to a 0.5T projecting position projecting to an inner side by 0.5 T (T isthickness of the inner coil member 10B in the radial direction of thestator core 2) from the reference position in the radial direction ofthe stator core 2. The first to twelfth inner base parts 42 a to 42 l atthe 0.5 T projecting position are shown by hatching patterns of linesextending from an upper left side to a lower right side.

The inner upper left arms 46 b, the inner lower left arms 48 b and theinner right ends 51 are located at a 1 T projecting position projectingto an inner side by 1 T from the reference position in the radialdirection of the stator core 2. The respective parts 46 b, 48 b and 52at the 1 T projecting position reference position are shown by hatchingpattern of lines extending upward and downward.

Inner upper right arm bending parts 61 bent to an inner side by 0.5 T inthe radial direction of the stator core 2 are formed on the inner upperright arms 46 a at joint portions connected to the second, fourth,sixth, eight and tenth inner base parts 42 b, 42 d, 42 f, 42 h and 42 j.

Inner upper left arm bending part 62 bent to an outer side by 0.5 T inthe radial direction of the stator core 2 are formed on the inner upperleft arms 46 b at joint portions connected to the third, fifth, seventh,ninth and eleventh inner base parts 42 c, 42 e, 42 g, 42 i and 42 k.

An inner upper arm connection part 47 is bent to an inner side by 1 T inthe radial direction of the stator core 2, from a right end (referenceposition) connected to the inner upper right arm 46 a to a left end (1 Tprojecting position) connected to the inner upper left arm 46 b.

Inner lower right arm bending parts 63 bent to an inner side by 0.5 T inthe radial direction of the stator core 2 are formed on the inner lowerright arms 48 a at joint portions connected to the first, third, fifth,seventh, ninth and eleventh inner base parts 42 a, 42 c, 42 e, 42 g, 42i and 42 k.

Inner lower left arm bending parts 64 bent to an outer side by 0.5 T inthe radial direction of the stator core 2 are formed on the inner lowerleft arms 48 b at joint portions connected to the second, fourth, sixth,eighth, tenth and twelfth inner base parts 42 b, 42 d, 42 f, 42 h, 42 jand 42 l.

An inner lower arm connection part 49 is bent to an inner side by 1 T inthe radial direction of the stator core 2 from a right end (referenceposition) connected to the inner lower right arm 48 a to a left end (1 Tprojecting position) connected to the inner lower left arm 48 b.

An inner right end bending part 65 bent to an outer side by 0.5 R in theradial direction of the stator core 2 is formed on an inner right end 51at a portion connected to the first inner base part 42 a.

An inner left end bending part 66 bent to an inner side by 0.5 T in theradial direction of the stator core 2 is formed on an inner left end 52at a portion connected to the twelfth inner base part 42 l.

As shown in FIG. 7, when two outer coil members 10A are aligned in thecircumferential direction of the stator core 2, the outer lower left arm18 b of the right outer coil member 10A and the outer lower right 18 aof the left outer coil member 10A are overlaid on each other, and theouter upper left arm 16 b of the right outer coil member 10A and theouter upper right arm 16 a of the left outer coil member 110A areoverlaid on each other. Also, at portions of FIGS. 7, 8, 14 to 16 wherethe coil members are overlaid on each other, overlaid deep side portionsare also illustrated by solid lines.

The outer coil member 10A is bent as described above, the outer lowerleft arm 18 b is positioned at the reference position, and the outerlower right arm 18 a is positioned at the 1 T projecting position.Accordingly, the outer lower left arm 18 b of the right outer coilmember 10A and the outer lower right arm 18 a of the left outer coilmember 10A are in contact with each other without any gap, but arearranged without interfering with each other.

Similarly, the outer upper left arm 16 b is positioned at a referenceposition, and the outer upper right arm 16 a is positioned at the 1 Tprojecting position. Accordingly, the outer upper left arm 16 b of theright outer coil member 10A and the outer upper right arm 16 a of theleft outer coil member 10A are in contact with each other without anygap, but are arranged without interfering with each other.

In this manner, the outer coil members 10A adjacent to each other in thecircumferential direction of the stator core 2 do not interfere witheach other, and therefore, as shown in FIG. 8, six outer coil members10A can be arranged in line in the circumferential direction of thestator core 2. In this embodiment, among the six outer coil members 10A,the outer coil member 10A at the left end is referred to as a firstouter coil member 10A, and the other outer coil members 10A are referredto as second, third to sixth outer coil members 10A sequentially in aright direction (a clockwise direction in the circumferential directionof the stator core 2).

Similarly, the inner coil members 10B adjacent to each other in thecircumferential direction of the stator core 2 do not interfere witheach other, and therefore, six inner coil members 10B can be arranged inline in the circumferential direction of the stator core 2. In thisembodiment, among the six inner coil members 10B, the inner coil member10B at the left end is referred to as a first inner coil member 10B, andthe other inner coil members 10B are referred to as second, third tosixth inner coil members 10B sequentially in a right direction (aclockwise direction in the circumferential direction of the stator core2).

As shown in FIG. 9, when the first to sixth outer coil members 10A arealigned in the circumferential direction of the stator core 2 toconstitute eight layers of the coil 3, the first to twelfth outer baseparts 12 a to 12 l of the first outer coil member 10A are inserted inthe first, seventh, thirteenth, nineteenth, twenty-fifth, thirty-first,thirty-seventh, forty-third, forty-ninth, fifty-fifth, sixty-first andsixty-seventh slots 2 a of the stator core 2.

As shown in FIG. 10, the first to twelfth outer base parts 12 a to 12 lof the second outer coil member 10A are inserted in the seventy-second,sixth, twelfth, eighteenth, twenty-fourth, thirtieth, thirty-sixth,forty-second, forty-eighth, fifty-fourth, sixtieth, and sixty-sixthslots 2 a of the stator core 2.

As shown in FIG. 11, similarly to the first and second outer coilmembers 10A, the first to twelfth outer base parts 12 a to 12 l of thethird to sixth outer coil members 10A are inserted in the slots 2 a ofthe stator core 2. Thereby, eight layers of the coil 3 are constituted.

In detail, the first to twelfth outer base parts 12 a to 12 l of thethird outer coil member 10A are inserted in the seventy-first, fifth,eleventh, seventeenth, twenty-third, twenty-ninth, thirty-fifth,forty-first, forty-seventh, fifty-third, fifty-ninth, and sixty-fifthslots 2 a of the stator core 2.

The first to twelfth outer base parts 12 a to 12 l of the fourth outercoil member 10A are inserted in the seventieth, fourth, tenth,sixteenth, twenty-second, twenty-eighth, thirty-fourth, fortieth,forty-sixth, fifty-second, fifty-eighth and sixty-fourth slots 2 a ofthe stator core 2.

The first to twelfth outer base parts 12 a to 12 l of the fifth outercoil member 10A are inserted in the sixty-ninth, third, ninth,fifteenth, twenty-first, twenty-seventh, thirty-third, thirty-ninth,forty-fifth, fifty-first, fifty-seventh and sixty-third slots 2 a of thestator core 2.

The first to twelfth outer base parts 12 a to 12 l of the sixth outercoil member 10A are inserted in the sixty-eighth, second, eighth,fourteenth, twentieth, twenty-sixth, thirty-second, thirty-eighth,forty-fourth, fiftieth, fifty-sixth, and sixty-second slots 2 a of thestator core 2.

When the first to sixth inner coil members 110B are aligned in thecircumferential direction of the stator core 2 to constituted sevenlayers of the coil 3, as shown in FIG. 12, the first to twelfth innerbase parts 42 a to 42 l of the sixth inner coil member 10B are insertedin the second, eighth, fourteenth, twentieth, twenty-sixth,thirty-second, thirty-eighth, forty-fourth, fiftieth, fifty-sixth,sixty-second, and sixty-eighth slots 2 a.

As shown in FIG. 13, similarly to the sixth inner coil member 10B, thefirst to twelfth outer base parts 12 a to 12 l of the fifth to firstinner coil members 10B are inserted in the slots 2 a of the stator core2. Thereby, seven layers of the coil 3 are constituted.

In detail, the first to twelfth inner base parts 42 a to 42 l of thefifth inner coil member 10B are inserted in the third, ninth, fifteenth,twenty-first, twenty-seventh, thirty-third, thirty-ninth, forty-fifth,fifty-first, fifty-seventh, sixty-third, and sixty-ninth slots 2 a.

The first to twelfth inner base parts 42 a to 42 l of the fourth innercoil member 10B are inserted in the fourth, tenth, sixteenth,twenty-second, twenty-eighth, thirty-fourth, fortieth, forty-sixth,fifty-second, fifty-eighth, sixty-fourth, and seventieth slots 2 a.

The first to twelfth inner base parts 42 a to 42 l of the third innercoil member 10B are inserted in the fifth, eleventh, seventeenth,twenty-third, twenty-ninth, thirty-fifth, forty-first, forty-seventh,fifty-third, fifty-ninth, sixty-fifth, and seventy-first slots 2 a.

The first to twelfth inner base parts 42 a to 42 l of the second innercoil member 10B are inserted in the sixth, twelfth, eighteenth,twenty-fourth, thirtieth, thirty-sixth, forty-second, forty-eighth,fifty-fourth, sixtieth, sixty-sixth, and seventy-second slots 2 a.

The first to twelfth inner base parts 42 a to 42 l of the first innercoil member 10B are inserted in the seventh, thirteenth, nineteenth,twenty-fifth, thirty-first, thirty-seventh, forty-third, forty-ninth,fifty-fifth, sixty-first, sixty-seventh, and first slots 2 a.

As shown in FIG. 14, when the first to sixth inner coil members 10Bconstituting seven layers are arranged to be overlaid on the first tosixth outer coil members 10A constituting eight layers, some portionsare not overlaid on each other. At this non-overlaying position, anouter upper right arm bending part 31, an outer upper left arm bendingpart 32, an outer lower right arm bending part 33, and an outer lowerleft arm bending part 34 of the outer coil member 10A are formed.Thereby, there is no need of changing thickness (width) of the outercoil member 10A, and there is no need of a processing step of changingthickness of the outer coil member 10A. Therefore, deterioration of theconductor resistance at the respective bending parts 31 to 34 anddeterioration of costs can be prevented. The non-overlaying position isa position at which the outer coil members 10A and the inner coilmembers 10B are not overlaid on each other, when the first to eighthlayers of the coil 3 are constituted.

When there is no non-overlaying position, there is a need of displacingthe bending part in the axial line direction of the stator core 2, solength in the axial line direction of the coil 3 becomes long. In thisembodiment, there is no need of displacing the outer upper right armbending part 31, the outer upper left arm bending part 32, the lowerright arm bending part 33 and the lower left arm bending part 34 in theaxial line direction of the stator core 2, and therefore, the length inthe axial line direction of the coil 3 can be prevented from beinglonger.

Similarly, at a position where the first to sixth outer coil members 10Aconstituting eight layers are not overlaid on the first to sixth innercoil members 10B constituting seven layers, the inner upper right armbending part 61, the inner upper left arm bending part 62, the innerlower right arm bending part 63, and the inner lower left arm bendingpart 64 of the inner coil member 10B are formed. Thereby, there is noneed of changing thickness (width) of the inner coil member 10B, andthere is no need of a processing step of changing thickness of the innercoil member 10B. Therefore, deterioration of the conductor resistance atthe respective bending parts 61 to 64 and deterioration of costs can beprevented.

FIG. 15 shows a status that the third left end inner coil member 10B isoverlaid on the first outer coil member 10A. FIG. 16 shows a status thatthe first inner coil member 10B is overlaid on the third outer coilmember 10A.

As shown in FIG. 15, when the inner coil member 10B constituting sevenlayers are overlaid on the outer coil member 10A constituting eightlayers, the outer upper left arm 16 b (reference position) of the outercoil member 10A constituting the eight layers is opposed to the innerupper right arm 46 a (reference position) of the inner coil member 10Bconstituting the seven layers. Also, the outer lower left arm 18 b(reference position) of the outer coil member 10A constituting the eightlayers is opposed to the inner lower right arm 48 a (reference position)of the inner coil member 10B constituting the seven layers.

As shown in FIG. 16, the outer upper right arm 16 a (1 T projectingposition) of the outer coil member 10A constituting the eight layers isopposed to the inner upper left arm 46 b (1 T projecting position) ofthe inner coil member 10B constituting the seven layers. Also, the outerlower right arm 18 a (1 T projecting position) of the outer coil member10A of the eight layers is opposed to the inner lower left arm 48 b (1 Tprojecting position) of the inner coil member 10B of the seven layers.

In this manner, the outer coil member 10A constituting the eight layersof the coil 3, and the inner coil member 10B constituting the sevenlayers of the coil 3 are opposed to each other at the same position(such as reference position, 1 T projecting position), and so they canbe overlaid on each other without interfering with each other.

In this embodiment, the inner right ends 51 and the inner left ends 52of the six inner coil members 10B constituting one layer of the coil 3are bent outward in the radial direction of the stator core 2. Thereby,the six inner coil members 10B constituting one layer of the coil 3 canbe prevented from contacting a rotor rotatably arranged inside thestator 1.

In the above-mentioned embodiment, the coil 3 is constituted by an8-layer coil member, but may be constituted by a plural-layer coilmember.

The outer coil member 10A may have such a shape that it is inverted witha center in the horizontal direction in FIG. 3, and the inner coilmember 10B may have such a shape that it is inverted with a center inthe horizontal direction in FIG. 5. In this case, the outer upper rightarm 16 a, the outer lower right arm 18 a, and the outer right end 21 areat the reference position, and the outer upper left arm 16 b, the outerlower left arm 18 b, and the outer left end 22 are at the 1 T projectingposition.

In the above-mentioned embodiment, the outer upper left arm bending part32 of the outer coil member 10A has an almost rectangular shape (two-dotlines in FIG. 18). This is because an angle A1 is about 90 degrees.

The outer upper left arm bending part 32 is not limited to an almostrectangular shape as described above, and may be formed in aparallelogram shape as shown in solid lines of FIG. 17. In this case, anangle A2 is made to be about 70 degrees, so that the outer upper leftarm bending part 32 can be formed into a parallelogram shape. The outerupper left arm bending part 32 is formed into a parallelogram shape, sothat, when compared to the bending part formed into an almostrectangular shape, the length of the outer upper left arm bending part32 (length of upper and lower faces of the outer upper left arm bendingpart 32) can be made long, and a load applied to the outer coil member10A in bending the outer upper left arm bending part 32 can be reduced.

As is similar to the outer upper left arm bending part 32, the outerupper right arm bending part 31, the outer lower right arm bending part33, the outer lower left arm bending part 34, the inner upper right armbending part 61, the inner upper left arm bending part 62, the innerlower right arm bending part 63, and the inner lower left arm bendingpart 64 may be formed into a parallelogram shape.

What is claimed is:
 1. A coil for a rotary electric machine that isformed into an annular shape by plural coil members, and that isinserted in plural slots formed on an annular stator of the rotaryelectric machine, wherein the plural coil members respectively compriseplural base parts inserted in the slots, extending in an axial linedirection of the coil, and having a gap in a circumferential directionof the coil, plural first connection parts projecting from one end ofthe slots and connecting ends of adjacent base parts to each other, andplural second connection parts projecting from the other end of theslots and connecting the other ends of the adjacent base parts to eachother, wherein the first and second connection parts respectivelycomprise two arms extending from one end and the other end of each ofthe adjacent base parts so that they approach to each other, and an armconnection part connecting the two arms, wherein the coil members arearranged in line in the circumferential direction of the coil, and areinserted in a same slot in a radial direction of the coil, and the coilmembers adjacent to each other in the same slot in the radial directionof the coil are phase-offset from each other and thus arranged, andwherein in each of the two arms, an arm bending part bent in the radialdirection of the coil is provided at a joint part of the arm, the jointpart being positioned not to overlap, in the radial direction of thecoil, the other coil member adjacent in the radial direction of thecoil.
 2. The coil for the rotary electric machine according to claim 1,wherein the arm connection part is bent in the radial direction of thecoil.
 3. The coil for the rotary electric machine according to claim 2,wherein the arm bending part is bent in one of an inner direction and anouter direction in the radial direction of the coil, and wherein the armconnection part is bent in the other of the inner direction and theouter direction in the radial direction of the coil.
 4. The coil for therotary electric machine according to claim 2, wherein the arm connectionpart extends in the circumferential direction of the coil.
 5. The coilfor the rotary electric machine according to claim 1, wherein the twoarms are bent at an angle of about 45 degrees in the circumferentialdirection of the coil.
 6. The coil for the rotary electric machineaccording to claim 1, wherein the two arms are bent plural times atdifferent angles in the circumferential direction of the coil.
 7. Thecoil for the rotary electric machine according to claim 1, wherein amongthe plural coil members, the arm bending part of a terminal end of thecoil member arranged on an innermost peripheral side in the radialdirection of the slot is bent in an outer direction of the radialdirection of the coil.
 8. The coil for the rotary electric machineaccording to claim 1, wherein one of the two arms is positioned at areference position in the radial direction of the coil, and the other ispositioned at a projection position at which it projects nearer an innerside than the reference position, and wherein among the two arms, armspositioned at the reference position of the coil members adjacent toeach other in the radial direction of the coil are faced to each other,and the other arms positioned at the projection position are faced toeach other.
 9. A rotary electric machine comprising a coil for therotary electric machine that is formed into an annular shape by pluralcoil members, and a stator that is formed in a cylindrical shape and onan inner periphery of which plural slots in which plural base parts ofthe coil for the rotary electric machine are inserted, are formed,wherein the plural coil members respectively comprise the plural baseparts inserted in the plural slots, extending in an axial line directionof the coil, and having a gap in a circumferential direction of thecoil, plural first connection parts projecting from one end of theplural slots and connecting ends of adjacent base parts to each other,and plural second connection parts projecting from the other end of theplural slots and connecting the other ends of the adjacent base parts toeach other, wherein the first and second connection parts respectivelycomprise two arms extending from one end and the other end of each ofthe adjacent base parts so that they approach to each other, and an armconnection part connecting the two arms, wherein the coil members arearranged in line in the circumferential direction of the coil, and areinserted in a same slot in a radial direction of the coil, and the coilmembers adjacent to each other in the same slot in the radial directionof the coil are phase-offset from each other and thus arranged, andwherein in each of the two arms, an arm bending part bent in the radialdirection of the coil is provided at a joint part of the arm, the jointpart being positioned not to overlap, in the radial direction of thecoil, the other coil member adjacent in the radial direction of thecoil.